Minimum quantity lubrication grinding performance assisted by ultrasonic vibrations and oil-based nanofluid

The Minimal Quantity Lubrication (MQL) method has advantages but is limited by high temperatures in the grinding zone that can damage the workpiece. This research aims to mitigate this risk by using an oil-based nanofluid and introducing ultrasonic vibrations (UV) during grinding. Dry grinding serves as a comparative reference. Under these conditions, a burn/non-burn diagram was developed, and variations in friction coefficient, tangential cutting force, and temperature were measured in relation to the depth of cut. The results revealed that, under dry grinding conditions, 75% of the workpieces experienced burning. However, the application of UV during dry grinding reduced the burn rate to 62.5%, along with an 8% reduction in the friction coefficient, a 15% reduction in tangential force, and a 12% decrease in temperature. Furthermore, when grinding was performed using an oil-based nanofluid containing Multi-Walled Carbon Nanotubes (MWCNTs) in conjunction with UV, the burn rate was significantly reduced to 31%. In this scenario, the friction coefficient, tangential force, and temperature showed substantial improvements, with reductions of 25%, 38%, and 36%, respectively. The results demonstrate that combining oil-based nanofluids with UV effectively enhances MQL grinding by reducing thermal damage and improving efficiency.